WO2011081874A1 - Composite inorganic particles and methods of making and using the same - Google Patents

Composite inorganic particles and methods of making and using the same Download PDF

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Publication number
WO2011081874A1
WO2011081874A1 PCT/US2010/060050 US2010060050W WO2011081874A1 WO 2011081874 A1 WO2011081874 A1 WO 2011081874A1 US 2010060050 W US2010060050 W US 2010060050W WO 2011081874 A1 WO2011081874 A1 WO 2011081874A1
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Prior art keywords
particles
metal oxide
inorganic particles
metal
composite inorganic
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PCT/US2010/060050
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English (en)
French (fr)
Inventor
Daniel Ray Fruge
Original Assignee
W. R. Grace & Co.-Conn.
Michos, Demetrius
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Application filed by W. R. Grace & Co.-Conn., Michos, Demetrius filed Critical W. R. Grace & Co.-Conn.
Priority to ES10841500.1T priority Critical patent/ES2647573T3/es
Priority to KR1020127019895A priority patent/KR101823170B1/ko
Priority to JP2012547102A priority patent/JP6012471B2/ja
Priority to CN201080060131.9A priority patent/CN102905887B8/zh
Priority to US13/519,748 priority patent/US9234104B2/en
Priority to EP10841500.1A priority patent/EP2555920B1/en
Priority to PL10841500T priority patent/PL2555920T3/pl
Publication of WO2011081874A1 publication Critical patent/WO2011081874A1/en
Priority to US14/957,884 priority patent/US20160083587A1/en

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    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/113—Silicon oxides; Hydrates thereof
    • C01B33/12—Silica; Hydrates thereof, e.g. lepidoic silicic acid
    • C01B33/18—Preparation of finely divided silica neither in sol nor in gel form; After-treatment thereof
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
    • C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
    • C09C3/06—Treatment with inorganic compounds
    • C09C3/063—Coating
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
    • C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
    • C09C1/28—Compounds of silicon
    • C09C1/30—Silicic acid
    • C09C1/3045—Treatment with inorganic compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
    • C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
    • C09C1/28—Compounds of silicon
    • C09C1/30—Silicic acid
    • C09C1/3045—Treatment with inorganic compounds
    • C09C1/3054—Coating
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
    • C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
    • C09C1/36—Compounds of titanium
    • C09C1/3607—Titanium dioxide
    • C09C1/3653—Treatment with inorganic compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
    • C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
    • C09C3/06—Treatment with inorganic compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/08—Anti-corrosive paints
    • C09D5/082—Anti-corrosive paints characterised by the anti-corrosive pigment
    • C09D5/084—Inorganic compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/61—Additives non-macromolecular inorganic
    • C09D7/62—Additives non-macromolecular inorganic modified by treatment with other compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/66—Additives characterised by particle size
    • C09D7/67—Particle size smaller than 100 nm
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/66—Additives characterised by particle size
    • C09D7/68—Particle size between 100-1000 nm
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/66—Additives characterised by particle size
    • C09D7/69—Particle size larger than 1000 nm
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/60—Particles characterised by their size
    • C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/60—Particles characterised by their size
    • C01P2004/62—Submicrometer sized, i.e. from 0.1-1 micrometer
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C08K3/36—Silica
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00—Use of pretreated ingredients
    • C08K9/02—Ingredients treated with inorganic substances
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
    • Y10T428/2991—Coated

Definitions

  • the present invention is directed to composite inorganic particles, compositions containing composite inorganic particles, methods of making composite inorganic particles, and methods of using composite inorganic particles.
  • metal oxide particles containing metal phosphate are highly desired.
  • coatings having metal phosphate materials may be applied to a variety of substrates for a variety of purposes such as corrosion resistance against harsh chemical environments at elevated temperatures, as fiber coatings to provide toughening of high temperature composites, as coatings for bio-active surfaces for implants, and, in general, for surface modification of a substrate to obtain desirable electrical, chemical, thermal and mechanical properties.
  • metal oxide particles containing metal phosphate that are stable in a dispersion or suspension. Moreover, there is a need in the art for metal oxide particles containing metal phosphate that are relatively small and/or uniform in size.
  • the present invention addresses some of the difficulties and problems discussed above by the discovery of new composite inorganic particles containing metal phosphate.
  • the composite inorganic particles have a particle size and particle size distribution, which allows them to remain in suspension for long periods of time. Moreover, the composite inorganic particles possess a composition and structure that provide for desirable amounts of available metal phosphate that is uniformly distributed on the surface of the particles.
  • the new composite inorganic particles are typically porous or non-porous, a metal oxide particles, and may be used as anti- corrosion agents, fillers, hardening agents, surface modification agents, and the like.
  • the new composite inorganic particles are particularly suitable for use in anti- corrosion coatings, paints, bio-active surface coatings, protective coatings, fillers for dental implants, fillers for ceramics, dopants for glasses, and the like.
  • a powder of composite inorganic particles of the present invention comprises metal phosphate and metal oxide wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • a powder of composite inorganic particles of the present invention comprises metal oxide and metal phosphate particles having a particle size distribution such that the median particle size is less than about 50 pm.
  • the mean particle size may be about 40 pm or less, about 30 pm or less, or from about 20 pm or less.
  • the median particle size may range about 0.001 pm to about 50 pm, from about 0.001 pm to about 40 pm, or about 0.001 pm to about 30 pm.
  • a powder of composite inorganic particles of the present invention comprises metal phosphate and metal oxide, wherein after being mixed with a liquid, forms a dispersion that remains stable for at least six months. In an alternative, embodiment, the dispersion remains stable for at least about one year.
  • a dispersion of composite inorganic particles of the present invention comprises metal phosphate and metal oxide wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • a dispersion of composite inorganic particles of the present invention comprises metal phosphate and metal oxide wherein the dispersion remains stable for at least six months. In an alternative, embodiment, the dispersion remains stable for at least about one year.
  • the present invention is also directed to methods of making composite inorganic particles.
  • the method of making composite inorganic particles comprises providing a metal oxide particles, forming a coating of metal phosphate on the metal oxide particles.
  • the method of making composite inorganic particles comprises providing metal oxide particles, forming a coating of metal phosphate on the metal oxide particles.
  • the composite inorganic particles may have a particle size distribution such that the median particle size is less than about 50 pm.
  • the method of making composite inorganic particles comprises providing metal oxide particles, forming a coating of metal phosphate on the metal oxide particles.
  • the dispersion may remain stable for at least six months, and even up to more than a year.
  • the present invention is further directed to methods of using composite inorganic particles.
  • the method comprises providing a powder of composite inorganic particles comprising metal phosphate and metal oxide; mixing the powder with a liquid to form a dispersion; and applying the dispersion to a substrate, wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • the method comprises providing a dispersion of liquid and composite inorganic particles, which comprise metal phosphate and metal oxide; and applying the dispersion to a substrate, wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • the present invention is directed to composite inorganic particles.
  • the present invention is further directed to methods of making composite inorganic particles, as well as methods of using composite inorganic particles.
  • a description of exemplary composite inorganic particles, methods of making composite inorganic particles, and methods of using composite inorganic particles are provided below.
  • inorganic means compounds that typically do not contain carbon atoms, except for some carbon containing compounds, such as for example, carbon monoxide, carbon dioxide, carbonates, cyanides, cyanates, carbides, and thyocyanates.
  • inorganic materials include, but are not limited to, oxides, sulfides, hydroxides, carbonates, silicates, phosphates, etc, and mixtures thereof.
  • metal oxides is defined as binary oxygen compounds where the metal is the cation and the oxide is the anion.
  • the metals may also include metalloids.
  • Metals include those elements on the left of the diagonal line drawn from boron to polonium on the periodic table.
  • Metalloids or semi-metals include those elements that are on this line. Examples of metal oxides include silica, alumina, titania, zirconia, etc., and mixtures thereof.
  • porous particles means particles having significant internal porosity as measured by nitrogen porisimetry, i.e., a porosity of more than about 0.05 cc/g
  • non-porous means particles having little or no internal porosity, i.e., an internal porosity of less than about 0.05 cc/g
  • porous particles include, silica gel, precipitated silica, fumed silica, boehmite alumina, etc.
  • non-porous particles include colloidal silica, alumina, titania, etc.
  • the composite inorganic particles of the present invention have a physical structure and properties that enable the composite inorganic particles to provide one or more advantages when compared to known composite inorganic particles.
  • the present invention addresses some of the difficulties and problems discussed above by the discovery of new composite inorganic particles containing metal phosphate and metal oxide.
  • the composite inorganic particles have properties, which provide improved stability when the composite inorganic particles are dispersed in a liquid.
  • the composite inorganic particles have a particle size and particle size distribution, which allows them to remain in suspension for long periods of time.
  • the composite inorganic particles possess a composition and structure that provide for desirable amounts of available metal phosphate that is uniformly distributed on the surface of the particles.
  • the new composite inorganic particles are typically porous or non-porous metal oxide and metal phosphate particles, and may be used as anti-corrosion agents, fillers, hardening agents, surface modification agents, and the like.
  • the new composite inorganic particles are particularly suitable for use in anti-corrosion coatings, paints, bio-active surface coatings, protective coatings, fillers for dental implants, fillers for ceramics, dopants for glasses, and the like.
  • a powder of composite inorganic particles of the present invention comprises metal phosphate and metal oxide wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • a powder of composite inorganic particles of the present invention comprises metal oxide and metal phosphate particles having a particle size distribution such that the median particle size is less than about 50 pm.
  • the mean particle size may be about 40 pm or less, about 30 pm or less, or from about 20 pm or less.
  • the median particle size may range about 0.001 pm to about 50 pm, from about 0.001 pm to about 40 pm, or about 0.001 pm to about 30 pm.
  • a powder of composite inorganic particles of the present invention comprises metal phosphate and metal oxide, wherein after being mixed with a liquid, forms a dispersion that remains stable for at least six months. In an alternative, embodiment, the dispersion remains stable for at least about one year.
  • a dispersion of composite inorganic particles of the present invention comprises metal phosphate and metal oxide wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • a dispersion of composite inorganic particles of the present invention comprises metal phosphate and metal oxide wherein the dispersion remains stable for at least six months. In an alternative, embodiment, the dispersion remains stable for at least about one year.
  • a composite particle of the present invention comprises composite inorganic particles having a particle size distribution such that the mean particle size is about 50 pm or less.
  • the particle size distribution may be such that the mean particle size is about 49 pm or less, about 48 pm or less, about 47 pm or less, 46 pm or less, 45 pm or less, 44 pm or less, 43 prn or less, 42 pm or less, 41 pm or less, 40 pm or less, 39 pm or less, 38 pm or less, 37 pm or less, 36 pm or less, 35 pm or less, 34 pm or less, 33 pm or less, 32 pm or less, 31 pm or less, 30 pm or less.
  • the median particle size of the composite particle may range about 0.001 pm to about 50 pm, from about 0.001 pm to about 40 pm, or about 0.001 pm to about 30 pm.
  • the composite inorganic particles of the present invention may have a pore volume as measured by nitrogen porosimetry of at least about 0.40 cc/g. In one exemplary embodiment of the present invention, the composite inorganic particles have a pore volume as measured by nitrogen porosimetry of from about 0.40 cc g to about 1.4 cc/g. In another exemplary embodiment of the present invention, the composite inorganic particles have a pore volume as measured by nitrogen porosimetry of from about 0.75 cc/g to about 1.1 cc/g.
  • composite inorganic particles of the present invention may have a surface area as measured by the BET nitrogen adsorption method (i.e., the Brunauer Emmet Teller method) of at least about 150 m 2 /g.
  • the composite inorganic particles have a BET surface area of from about 400 m 2 /g to about 700 m 2 /g.
  • the composite inorganic particles have a BET surface area of from about 450 m 2 /g to about 500 m /g.
  • the metal oxide core comprises any porous or nonporous particles formed via any known process including, but not limited to, a solution polymerization process such as for forming colloidal particles, a continuous flame hydrolysis technique such as for forming fused particles, a gel technique such as for forming gelled particles, and a precipitation technique such as for forming precipitated particles.
  • the particles may be composed of inorganic materials.
  • the core particles are composed of inorganic materials such as metal oxides, sulfides, hydroxides, carbonates, silicates, phosphates, etc, but are preferably metal oxides.
  • the particles may be a variety of different symmetrical, asymmetrical or irregular shapes, including chain, rod or lath shape.
  • the particles may have different structures including amorphous or crystalline, etc.
  • the particles may include mixtures of particles comprising different compositions, sizes, shapes or physical structures, or that may be the same except for different surface treatments.
  • the metal oxide core particulates comprises porous materials, such as precipitated metal oxide (e.g., silica, alumina, titania, etc.), metal oxide gel, or fumed metal oxide.
  • precipitated metal oxide e.g., silica, alumina, titania, etc.
  • metal oxide gel e.g., metal oxide gel
  • fumed metal oxide e.g., fumed metal oxide.
  • the formation of precipitated silica occurs in a reaction between waterglass and an acid via first forming a seed of primary particles which can be grown to larger particles, followed by an aggregation and then by an agglomeration of these aggregates.
  • the agglomerates can be grown even more together by a so called reinforcement.
  • the hydrous silica begins to settle from the reaction slurry as a precipitate.
  • the precipitate is filtered from the slurry and washed.
  • the resulting filter cake then is dried using drying equipment as known in the art.
  • a stiffening of the silica structure will occur during the drying step in which irreversible Si-O-Si-links are formed from initial silanol groups.
  • Processes for making precipitated metal oxides include those set forth in U.S. Patents Nos. 7,037,47581 ; 5,030,286 and 4,157,920, the entire subject matter of which is incorporated herein by reference.
  • the metal oxide particles stem from the primary particles, grown particles, aggregated particles, agglomerated particles or the filter cake of a general metal oxide precipitation process as described above.
  • a silica gel is prepared by mixing an aqueous solution of an alkali metal silicate (e.g., sodium silicate) with a strong acid such as nitric or sulfuric acid, the mixing being done under suitable conditions of agitation to form a clear silica sol which sets into a hydrogel, i.e., macrogel, in less than about one-half hour. The resulting gel is then washed.
  • an alkali metal silicate e.g., sodium silicate
  • a strong acid such as nitric or sulfuric acid
  • the concentration of metal oxide, i.e., SiOa, formed in the hydrogel is usually in the range of about 10 and about 50 weight percent, with the pH of that gel being from about 1 to about 9, preferably 1 to about 4.
  • a wide range of mixing temperatures can be employed, this range being typically from about 20 to about 50°C.
  • the newly formed hydrogels are washed simply by immersion in a continuously moving stream of water which leaches out the undesirable salts, leaving about 99.5 weight percent or more pure metal oxide behind.
  • the pH, temperature, and duration of the wash water will influence the physical properties of the silica, such as surface area (SA) and pore volume (PV).
  • Silica gel washed at 65-90°C at pH's of 8-9 for 15-36 hours will usually have SA's of 250-400 and form aerogels with PVs of 1.4 to 1.7 cc gm.
  • Silica gel washed at pH's of 3-5 at 50-65°C for 15-25 hours will have SA's of 700- 850 and form aerogels with PV's of 0.6-1.3. These measurements are generated by 2 porosity analysis.
  • Methods for preparing metal oxide gels such as alumina and mixed metal oxide gels such as silica/aiumina cogels are also well known in the art. Methods for preparing such gels are disclosed in U.S. Patents 4,226,743, the contents of which are incorporated by reference.
  • alumina gels are prepared by mixing alkali metal aluminates and aluminum sulfate.
  • Cogels are prepared by cogelling two metal oxides so that the gels are composited together.
  • silica alumina cogels can be prepared by gelling an alkali metal silicate with an acid or acid salt, and then adding alkali metal aluminate, aging the mixture and subsequently adding aluminum sulfate. The gel is then washed using conventional techniques.
  • the metal oxide particles comprise nonporous metal oxides, such as colloidal metal oxide particles.
  • Colloidal metal oxides include those particles originating from dispersions or sols in which the particles do not settle from dispersion over relatively long periods of time. Such particles are typically below one micron in size.
  • Colloidal metal oxides having an average particle size in the range of about 1 to about 300 nanometers and processes for making the same are well known in the art. See U.S. Patents 2,244,325; 2,574,902; 2,577,484; 2,577,485; 2,631 ,134; 2,750,345; 2,892,797; 3,012,972; and 3,440,174, the contents of which are incorporated herein by reference.
  • the colloidal metal oxide particles may be colloidal silicas having average particle sizes in the range of 5 to 100 nanometers.
  • Colloidal silicas can have a surface area (as measured by BET) in the range of 9 to about 2700 m 2 /g.
  • the metal oxide core particles possess a mean particle size of about 40 ⁇ or less, about 30 ⁇ or less, or about 20 pm or less. In another exemplary embodiment, the metal oxide core particles possess a median particle size range from about 0.001 pm to about 50 ⁇ , from about 0.001 ⁇ to about 40 ⁇ , or from about 0.001 pm to about 30 ⁇ . In a further exemplary embodiment, the metal oxide core particles possess a mean particle size of about 10 microns or less, or about 9, 8, 7, 6, 5, 4, 3, 2 or even 1 microns or less.
  • the composite inorganic particles include the metal oxide core with a coating comprising metal phosphate formed thereon.
  • the coating may be continuous or discontinuous.
  • the metal phosphate may be calcium phosphate.
  • the amount of metal phosphate deposited on the metal oxide core varies depending on the reaction conditions.
  • the composite inorganic particles comprise weight of metal to weight of metal oxide ratio (wtM/wtMO x ) of about 0.001 to about 0.5 in the composite inorganic particles, or from about 0.001 to about 0.4, or from about 0.001 to about 0.3, or even from about 0.001 to about 0.2.
  • the present invention is also directed to methods of making composite inorganic particles.
  • the method of making composite inorganic particles comprises providing metal oxide particles, forming a coating of metal phosphate on the metal oxide particles.
  • the method of making composite inorganic particles comprises providing metal oxide particles, forming a coating of metal phosphate on the metal oxide particles.
  • the composite inorganic particles may have a particle size distribution such that the median particle size is less than about 50 pm.
  • the metal oxide core particles possess a mean particle size of about 40 pm or less, about 30 pm or less, or about 20 pm or less.
  • the metal oxide core particles possess a median particle size range from about 0.001 pm to about 50 ⁇ , from about 0.001 pm to about 40 ⁇ , or from about 0.001 pm to about 30 pm.
  • the method of making composite inorganic particles comprises providing metal oxide particles, forming a coating of metal phosphate on the metal oxide particles.
  • the dispersion may remain stable for at least six months, and even up to more than a year.
  • the metal oxide particles are formed prior to formation of the composite inorganic particles.
  • Raw materials used to form the metal oxide particles and composite inorganic particles of the present invention, as well as method steps for forming the metal oxide particles and composite inorganic particles of the present invention are discussed below.
  • metal oxide particles of the present invention may be formed from a number of metal oxide-containing raw materials.
  • suitable raw materials for making silica include, but are not limited to, metal silicates, such as alkali metal silicates.
  • metal silicates such as alkali metal silicates.
  • the reactants and process conditions will vary as set forth herein.
  • silica gel is selected as the metal oxide core particles, they are prepared by the above-mentioned process for making gels. After washing, the gel is dried. Drying rate has an effect on the surface area and pore volume of the final metal oxide particles.
  • the drying step comprises spreading a decanted volume or filter cake of silica product into a tray so as to form a silica cake thickness of about 1.25 cm; placing the tray containing the silica cake in a gravity convection oven for about 20 hours at an oven temperature of about 140°C; removing the tray and silica from the oven; and collecting the silica.
  • the dried silica material is then milled and/or classified to prepare a powder having a mean particle size of about 50 ⁇ or less.
  • the metal oxide core particles possess a mean particle size of about 40 pm or less, about 30 ⁇ or less, or about 20 ⁇ or less.
  • the metal oxide core particles possess a median particle size range from about 0.001 pm to about 50 ⁇ , from about 0.001 ⁇ to about 40 ⁇ , or from about 0.001 ⁇ to about 30 ⁇ .
  • the particles are then ready for subsequent preparation of the composite inorganic particles.
  • the method of making composite inorganic particles comprises forming a dispersion of metal oxide core particles and adding solutions of metal salts and phosphate salts thereto at a basic pH (e.g., 7-14) while stirring the mixture.
  • the mole ratio of metal salt to phosphate salt may be any range, but in the range of 1.0 to 2.0.
  • the metal and phosphate reagents may be added over a period of time, e.g., up to several hours, but is typically less than one hour.
  • the basic pH is maintained during the reaction with the appropriate bases, including but not limited to, potassium hydroxide, sodium hydroxide, ammonium hydroxide, etc., or mixtures thereof.
  • the resulting slurry is washed and filtered/ultrafiltered in order to remove any salts formed during the reaction.
  • the resulting slurry is stable for long periods of time, even for more than one year.
  • the metal content for the metal component in the resulting composite inorganic particles ranges from about 0.01 to about 0.50 based on the weight of metal oxide in the composite inorganic particles.
  • the solids content in the resulting composite inorganic particle dispersions range from about 1 to about 40 wt% based on the total weight of the dispersion.
  • the dispersions comprising composite inorganic particulates are drained to form a filter cake and then dried, or are simply spray dried.
  • the present invention is further directed to methods of using composite inorganic particles.
  • the composite inorganic particles may be used in a variety of applications, including as anticorrosion agents in anticorrosion coating applications, as pigments for other coating applications, as filler in biocompatible or ceramic applications, as an active component in dental cements, as a hardener in protective coatings, as a surface modifier in coatings for surface modification of a substrate to obtain desirable electrical, chemical, thermal and mechanical properties, and the like.
  • the method comprises providing a powder of composite inorganic particles comprising metal phosphate and metal oxide; mixing the powder with a liquid to form a dispersion; and applying the dispersion to a substrate, wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • the method comprises providing a dispersion of liquid and composite inorganic particles, which comprise metal phosphate and metal oxide; and applying the dispersion to a substrate, wherein the particles have a metal oxide core and a coating of metal phosphate on the metal oxide core.
  • the composite inorganic particles may have a particle size distribution such that the median particle size is less than about 50 ⁇ .
  • the dispersion may include various other components and/or be utilized in other formulations depending upon the desired application.
  • the composite inorganic particles are intended for use in an anticorrosion coating formulation, the composite inorganic particles are added to the formulation as powder, dispersions or pastes. If the composite metal particles are utilized in dental cements, they may be added as powder, dispersions or pastes.
  • the colloidal silica is made using the process set forth in US Patent No. 2,631,134.
  • the reaction is carried out by the simultaneous addition of silicate and resin to a reaction vessel while continuously withdrawing the silica sol thus formed.
  • the reaction is carried out in a four liter stainless steel beaker with an overflow pipe, which maintains the contents of the beaker at two liters; at the outset the beaker is filled with water.
  • a solution of sodium silicate (3.25 Si0 2 :Na 2 0, 10 per cent S1O2) is fed into the beaker at a rate of 25 ml./min.
  • 600g of the colloidal silica slurry (40% Si0 2 ) is placed in a beaker.
  • three separate reagents are added at the same time with good mixing using a conventional beaker mixer. All additions are performed at room temperature.
  • the fist reagent (2000g) added to the mixture is a 3wt% solution of Ca(N0 3 )2.4H 2 0 (based on the weight of the solution).
  • the second reagent (1200g) added to the mixture is a 3wt% solution of Na 2 HP0 4 .
  • the third reagent added to the mixture is a 2wt% solution of NaOH.
  • the calcium and phosphate reagents are added at such a rate as to add the full amounts in 40 minutes.
  • the pH is maintained at 9.5 by the appropriate addition of NaOH, in this example, 355g of the above- mentioned 2wt% solution of NaOH are used.
  • the slurry is ultrafiltered in order to remove salts generated during the reaction.
  • the final composite calcium phosphate silica particle dispersion is stable (i.e., the particles do not precipitate) and the particles possess a Ca/P mole ratio of 1.67 and a wtCa/wtSi02 of 0.04.
  • the pH of the dispersion is 9.4 and the solids content is 21.3 wt% based on the total weight of the dispersion (obtained by drying at 205°C to constant weight). The dispersion remains stable for at least six months.
  • Example 1 The process of Example 1 is repeated but using half of the amounts of calcium nitrate and sodium phosphate. These reagents are added over a period of 19 minutes.
  • the final composite calcium phosphate silica particle dispersion is stable and the particles possess a Ca/P mole ratio of 1.68 and a wtCa/wtSiOa of 0.02.
  • the pH of the dispersion is 9.3 and the solids content is 19.2 wt% based on the total weight of the dispersion.
  • the dispersion remains stable for at least six months.
  • Example 1 The process of Example 1 is repeated but using 800g of 7 nm colloidal silica slurry (30% Si02) prepared by the process recited in Example 1.
  • the smaller particles are formed by using less reaction time and the lower solids is provided using less evaporation time.
  • the other amounts of reactants utilized are the same as those set forth in Example 1.
  • the final composite calcium phosphate silica particle dispersion is stable and the particles possess a Ca/P mole ratio of 1.71 and a wtCa/wtSi0 2 of 0.04.
  • the pH of the dispersion is 9.5 and the solids content is 21.6 wt% based on the total weight of the dispersion.
  • the dispersion remains stable for at least six months.
  • Example 3 The process of Example 3 is repeated but using half of the amounts of calcium nitrate and sodium phosphate.
  • the other amounts of reactants utilized are the same as those set forth in Example 1.
  • the final composite calcium phosphate silica particle dispersion is stable and the particles possess a Ca/P mole ratio of 1.99 and a wtCa wtSi0 2 of 0.02.
  • the pH of the dispersion is 9.5 and the solids content is 21.6 wt% based on the total weight of the dispersion.
  • the dispersion remains stable for at least six months.
  • Silica gel is made according to the process recited herein and in U.S. Patent No. 6,380,265.
  • silica gel is prepared by mixing an aqueous solution of an alkali metal silicate (e.g., sodium silicate) with a sulfuric acid, the mixing being done under suitable conditions of agitation to form a clear silica sol which sets into a hydrogel, i.e., macrogel, in less than about one-half hour. The resulting gel is then washed.
  • the concentration of metal oxide, i.e., Si0 2 formed in the hydrogel is usually in the range of about 19 weight percent, with the pH of that gel being from about 1.5.
  • a wide range of mixing temperatures can be employed, this temperature being about 27°C.
  • the newly formed hydrogels are washed simply by immersion in a continuously moving stream of water which leaches out the undesirable salts, leaving about 99.5 weight percent or more pure metal oxide behind.
  • Silica gel is washed at about 80°C at a pH of about 8 for about 25 hours.
  • the silica gel is drained, dried and then milled to form a powder having a surface area of 270m 2 /g, a pore volume of 1.2cc/g and a median particle size of 6 microns.
  • 528g of the silica powder is dispersed in 792g of deionized water and the pH is adjusted to 9.5 with 2wt% sodium hydroxide. All additions are performed at room temperature.
  • R RL + k(Ru -RL), where k is a variable ranging from 1 % to 100% with a 1% increment, e.g., k is 1%, 2%, 3%, 4%, 5%. ... 50%, 51%, 52%. ... 95%, 96%, 97%, 98%, 99%, or 100%.
  • any numerical range represented by any two values of R, as calculated above is also specifically disclosed. Any modifications of the invention, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description and accompanying drawings. Such modifications are intended to fall within the scope of the appended claims.

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  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Inorganic Chemistry (AREA)
  • Nanotechnology (AREA)
  • Silicon Compounds (AREA)
  • Pigments, Carbon Blacks, Or Wood Stains (AREA)
  • Cosmetics (AREA)
  • Oxygen, Ozone, And Oxides In General (AREA)
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JP2012547102A JP6012471B2 (ja) 2009-12-29 2010-12-13 複合無機粒子及びそれを製造及び使用する方法
CN201080060131.9A CN102905887B8 (zh) 2009-12-29 2010-12-13 复合无机颗粒以及制备和使用它们的方法
US13/519,748 US9234104B2 (en) 2009-12-29 2010-12-13 Composite metal oxide particles and methods of making and using the same
EP10841500.1A EP2555920B1 (en) 2009-12-29 2010-12-13 Composite inorganic particles and methods of making and using the same
PL10841500T PL2555920T3 (pl) 2009-12-29 2010-12-13 Kompozytowe cząstki nieorganiczne i sposób ich wytwarzania oraz ich zastosowanie
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DE102011078720A1 (de) * 2011-07-06 2013-01-10 Evonik Degussa Gmbh Pulver enthaltend mit Polymer beschichtete Kernpartikel enthaltend Metalle, Metalloxide, Metall- oder Halbmetallnitride
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EP2883917A1 (de) * 2013-12-13 2015-06-17 Kronos International, Inc. Calciumphosphat-haltige Kompositpigmente und Verfahren zu ihrer Herstellung
WO2015086146A1 (de) * 2013-12-13 2015-06-18 Kronos International, Inc. Calciumphosphat-haltige titandioxid-kompositpigmente und verfahren zu ihrer herstellung
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WO2021183602A1 (en) 2020-03-10 2021-09-16 Sasol (Usa) Corporation Alumina modified with a short chain carboxylic acid for use as a coating and a method for producing the same

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US9234104B2 (en) 2016-01-12
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